Decorative covering for walls of humid environments and/or subject to water jets and process of application thereof

ABSTRACT

The present invention relates to a decorative sheath for walls of humid environments and/or subject to water jets, of the type that comprises in succession: —a reinforcing material layer (2) to be applied on the surface of the wall (1) of a humid environment; —a waterproofing glue layer (3); —a decorated fibreglass fabric layer (4), having the decorative appearance to be conferred to said wall (1); —a protective finishing layer (5) for said fibreglass fabric layer (4). Said sheath provides that a sealant layer (6) to be applied only on the junction points of the sheath is provided.

The present invention relates to a decorative sheath for walls of humid environments and/or subject to water jets and relative application process.

The use of decorative sheaths for walls in environments which present particular application problems, in particular by expert operators, has been known for a long time.

A specific and particular case, however, is constituted by the application of said sheath systems in humid environments; let's think, for example, about the walls of bathrooms, showers, laundries or other similar environments. In particular, it is known to use, under a normal covering in tiles and ceramics, products such as elastic and cementitious sheaths or the like, which prevent the water from penetrating into the underlying areas, thus avoiding the formation of humidity, water stagnation, condensation and molds.

In general, the laying technique with which one has to work on a new type of construction or in the case of total renovation of a particular environment is simple; vice versa, it is much more complicated if the waterproofing of an indoor environment is required without the possibility of being able to remove the existing coverings. The thing is all the more complex if one thinks that it is necessary to obtain a final aesthetic result that is satisfactory.

In fact, in most of the applications of the known type, the decorative element is not an integral part of the waterproofing systems, since the waterproof sheaths are not finished decorative products.

In recent times, decorative sheath systems have become widespread which are waterproof for walls in humid indoor environments, such as those mentioned above; this sheath can also be laid on already existing coverings, requiring no intervention for the removal of any materials already present on the surfaces to be treated.

In the publication relating to patent application EP2995741 A1, a system of waterproof decorative sheath for walls in humid environments is described, as well as its relative manufacturing process is described. Thanks to this system, a decorative sheath is obtained which is waterproof for walls in humid indoor environments and which can also be laid on already existing coverings. Furthermore, this decorative sheath already constitutes a finished product in itself, in the sense that it already allows to confer the desired final aesthetic appearance to the wall in which it is laid.

However, this system is rather complicated and time-consuming to apply, since it requires the application of a considerable plurality of layers arranged in succession on the wall to be decorated, which also entails considerable time required for their application. Furthermore, precisely due to the fact that this sheath has a considerable number of layers, this necessarily entails an increase in the overall costs of the sheath itself.

The following state-of-the-art documents are also cited: DE 19811152 A1, DE 10201867 A1, EP 2551318 A2, US 2004/203307 A1, US 2003/198804 A1 and DE 202006019916.

The object of the present invention is to realise a sheath for walls in humid environments and/or subject to water jets which, once installed, is capable of conferring a wall its desired final appearance and which is free from the aforementioned drawbacks. In particular, this sheath must be simpler to install, as well as intrinsically cheaper, while ensuring the same results from the aesthetic point of view with respect to similar sheaths of the known type.

The same considerations must also apply to the process suitable for enabling the installation of said sheath.

This is achieved, according to the invention, by providing a sheath which has the characteristics of claim 1 and a process for the application of the aforesaid one, which has the characteristics of claim 7.

Further characteristics of the invention are better defined in the dependent claims.

These and other characteristics of the invention will now be described in detail hereinafter, with reference to some particular embodiments of the sheath and of the process, with reference to the attached FIGURE, in which;

FIG. 1 illustrates the succession of layers which make up the sheath according to the invention applied to the surface of a wall.

As visible in FIG. 1, the invention consists of a sheath, comprising a plurality of layers of material to be applied at a wall 1 of a humid environment. In particular, this wall 1 can be constituted by any wall subjected to being wetted by water jets; by way of non-limiting example, the walls present at shower trays and bathtubs, with relative pipes carrying water, are cited. It is understood that, obviously, the invention can also be applied in any other situation, different from the preceding ones, in which for any reason the wall is hit by water or other liquids. By way of example, any walls present at fountains, water features and the like are cited. Furthermore, it should be noted that the invention can also be used at external walls of buildings which, obviously, are intended to be subjected to the influence of water jets for atmospheric reasons. According to the invention, as a first step, a layer of consolidating material 2 will be applied to the wall 1. Advantageously, said layer will be made by means of a solvent-free transparent epoxy formulation. In particular, it is convenient to use a two-component product based on epoxy resins, used in combination with cycloaliphatic amine hardeners. This product has an excellent penetrating and consolidating power for concrete supports. The particular chemical structure of the amine hardener is able to guarantee a good reactivity of the system even at low temperatures. By way of non-limiting example, the possibility of using the SUPERPRINK® product, produced by the company Teknai Srl of Gallarate (VA), should be noted. From an operational point of view, in most cases the operation will be on concrete substrates; in this case it is necessary to check that there is no rising humidity. If the concrete is of new construction, the complete cure thereof must be awaited. Before applying the layer of consolidating material, which is generally defined as “improving primer”, the surface must be solid, absorbent and free from the presence of oils, surfactants, water, dust. Any inconsistent parts must be removed. Since, advantageously, the formulation is made in two components (A and B), it will be necessary to combine component A with component B in a single container and mix them carefully using a mechanical mixer for about two minutes. Subsequently, the product will be applied by roller, pure or diluted with 5-10% alcohol to increase the penetrability thereof. Before proceeding further, it is necessary to wait for a period of 12-36 hours.

Subsequently, in the second step, a layer of waterproofing glue 3 is applied. The aforesaid one is essentially constituted by a product that is silane-modified polymer-based of semi-transparent appearance. In fact, the product is a ready-to-use single-component. The product is spread evenly directly on the wall with a notched trowel or with a short-haired wool roller, proceeding in portions corresponding to just over the width of the cloth. By way of non-limiting example, the material called SPECIAL MS produced by the company ACM sas in Bareggio (MI) can be used for this layer of glue. This product has a so-called “open” time of about 30 minutes; this is the time that must elapse between the application of the adhesive and the subsequent application of the decorative layer of fibreglass for the success of the operation.

Once this “open” time has been respected, it is moved on to the third step by applying a layer of decorated fibreglass 4, which has the ornamental aspect that is to be conferred to said wall. As a non-limiting example, the material called GAVATEX of the company Gavazzi Tessuti Tecnici Spa S.U., based in Calolziocorte (LC), can be used for this decorated fibreglass layer. This material has the following characteristics:

THREADS NO. Warp 81 ± 1/dm THREADS Warp SP Apr. 2, 2010 Weft 50 ± 1/dm (UNI EN 1049-2) Weft WEIGHT Raw fabric 225 g/m² ± 10% Weight Raw fabric SP Apr. 2, 2012 Finished fabric 280 g/m² ± 15% (ISO 3374) Finished fabric

From an operational point of view, it is proceeded by cutting the fabric, abounding by about 5-10 cm compared to the height of the wall. The inner side of the fabric is applied to the wall in the unrolling direction, checking the vertical position thereof. If the laying is not perfect, the cloth is removed and then repositioned. By moving the cloths closer, one will make sure that the continuity of the pattern is guaranteed; then it is lightly pressed with plastic spatulas from the centre upwards and downwards, eliminating any air bubbles, in order to ensure perfect adhesion. Finally, any excess glue will be removed immediately, without using water and by trimming with a cutter and allowing the whole dry.

In the fourth step, a protective finishing layer 5, normally called “glass finish”, is applied. It is a transparent single-component polyurethane formulation in aqueous emulsion. By way of non-limiting example, the product called KAPPA HT PLUS® of the company Teknai Srl can be used. From the operational point of view, after having thoroughly cleaned the layer of fibre fabric, by eliminating any dusty residues present thereon, the product is applied with two different coats; in this regard, the use of a long-haired roller, by cross rolling, has proved to be particularly advantageous.

In the fifth and last step, the sheath is completed by applying a layer of sealant material 6 to be applied only on the junction points of the sheath. In this regard, the use of a single-component elastomeric sealant based on hygro-hardening aromatic polyurethane resins has proved to be particularly advantageous. By way of non-limiting example, the product called JOINT® of the company Teknai Srl mentioned above may be used. In most cases this sealant is placed in a syringe container, which has a special manual gun, which will be applied in the contact areas, such as, for example, between shower tray and wall, between bathtub and wall, between wall and wall, and finally between wall and tapware.

Tests carried out have undoubtedly made it possible to ascertain that by using this type of sheath and its relative application process it is possible to create surface coverings in humid environments and/or subject to water jets that substantially have the same aesthetic potential of similar sheaths of the known type.

However, the same tests carried out have made it possible to ascertain that the application time of the sheath according to the invention is significantly reduced with respect to that typical of sheaths of the known type.

Moreover, thanks to the presence of a lower number of component layers than that of the sheaths of the known type, the cost of the sheath is significantly reduced. This enables stating that the objects set forth above of the present invention have been completely achieved by means of the sheath and the relative application process previously illustrated and described.

It should be noted that the present invention may also assume different forms and aspects, as well as different methods of application with respect to what has been illustrated and described above, without prejudice to its essential characteristics, provided that everything falls within the scope of protection of the attached claims. 

1-8. (canceled)
 9. DECORATIVE SHEATH FOR WALLS OF HUMID ENVIRONMENTS AND/OR SUBJECT TO WATER JETS, of the type that comprises in succession: a reinforcing material layer to be applied on the surface of the wall of a humid environment; a waterproofing glue layer; a decorated fibreglass fabric layer, having the decorative appearance to be conferred to said wall; a protective finishing layer (5) for said fibreglass fabric layer wherein a sealant layer to be applied only on the junction points of the sheath is provided and the reinforcing material layer consists of an epoxy resin formulation, used in combination with cycloaliphatic amine hardeners, solvent-free and advantageously made in two components, adapted to be mixed just before applying the layer to the wall.
 10. DECORATIVE SHEATH, according to claim 9, wherein the waterproofing glue layer is made by means of a silane-modified polymer-based adhesive of semi-transparent appearance.
 11. DECORATIVE SHEATH, according to claim 9, wherein the decorated fibreglass fabric layer has the following characteristics: THREADS Warp 81 ± 1/dm SP Apr. 2, 2010 Weft 50 ± 1/dm (UNI EN 1049-2) WEIGHT Raw fabric 225 g/m² ± 10% SP Apr. 2, 2012 (ISO 3374)


12. DECORATIVE SHEATH, according to claim 9, wherein the protective finishing layer for said fibreglass fabric layer consists of a transparent single-component polyurethane formulation in aqueous emulsion.
 13. DECORATIVE SHEATH, according to claim 9, wherein the sealant layer consists of a single-component elastomeric sealant based on hygro-hardening aromatic polyurethane resins.
 14. PROCESS FOR THE APPLICATION OF A DECORATIVE SHEATH FOR WALLS OF HUMID ENVIRONMENTS AND/OR SUBJECT TO WATER JETS, of the type that comprises the following steps: applying a reinforcing material layer on the surface of the wall of a humid environment; applying a waterproofing glue layer on the reinforcing material layer; applying a decorated fibreglass fabric layer on said waterproofing glue layer, having the ornamental appearance to be conferred to said wall; applying a protective finishing layer on said decorated fibreglass fabric layer for the aforesaid wherein it comprises also the application of a sealant layer on said protective finishing layer, to be applied only on the junction points of the sheath, in particular in the contact areas between shower tray and wall, between bathtub and wall, between wall and wall, and finally between wall and tapware and the reinforcing material layer consists of a formulation based on epoxy resins, used in combination with cycloaliphatic amine hardeners, solvent-free and advantageously made of two components which are mixed just before applying the layer to the wall.
 15. PROCESS, according to claim 14, wherein the reinforcing material layer, to be applied on the surface of the wall of a humid environment, is obtained by carefully mixing, just before the application, the two components in which it is formulated and then it is applied by roller on the wall.
 16. PROCESS, according to claim 14, wherein the protective finishing layer for the decorated fibreglass fabric layer is applied in two coats. 